US6279471B1 - Drilling fluid recovery defluidization system - Google Patents
Drilling fluid recovery defluidization system Download PDFInfo
- Publication number
- US6279471B1 US6279471B1 US09/454,081 US45408199A US6279471B1 US 6279471 B1 US6279471 B1 US 6279471B1 US 45408199 A US45408199 A US 45408199A US 6279471 B1 US6279471 B1 US 6279471B1
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- 239000012530 fluid Substances 0.000 title claims description 67
- 238000011084 recovery Methods 0.000 title claims description 19
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- 238000000034 method Methods 0.000 claims abstract description 20
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B9/00—Presses specially adapted for particular purposes
- B30B9/02—Presses specially adapted for particular purposes for squeezing-out liquid from liquid-containing material, e.g. juice from fruits, oil from oil-containing material
- B30B9/12—Presses specially adapted for particular purposes for squeezing-out liquid from liquid-containing material, e.g. juice from fruits, oil from oil-containing material using pressing worms or screws co-operating with a permeable casing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B9/00—Presses specially adapted for particular purposes
- B30B9/02—Presses specially adapted for particular purposes for squeezing-out liquid from liquid-containing material, e.g. juice from fruits, oil from oil-containing material
- B30B9/12—Presses specially adapted for particular purposes for squeezing-out liquid from liquid-containing material, e.g. juice from fruits, oil from oil-containing material using pressing worms or screws co-operating with a permeable casing
- B30B9/18—Presses specially adapted for particular purposes for squeezing-out liquid from liquid-containing material, e.g. juice from fruits, oil from oil-containing material using pressing worms or screws co-operating with a permeable casing with means for adjusting the outlet for the solid
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/06—Arrangements for treating drilling fluids outside the borehole
- E21B21/063—Arrangements for treating drilling fluids outside the borehole by separating components
- E21B21/065—Separating solids from drilling fluids
- E21B21/066—Separating solids from drilling fluids with further treatment of the solids, e.g. for disposal
Definitions
- the field of the present invention relates generally to the recovery of drilling fluids from discharge cuttings fluids from a drilling/production operation, more particularly, a method utilizing various types of presses for the recovery of such drilling fluids through compaction and defluidization of entrained solids in a cuttings slurry prior to such cuttings being injected into a well casing or in conjunction with other environmental distribution and/or disposal operations.
- drilling fluid containing additives is circulated downwardly through the drill string to lubricate and remove cuttings from the bit.
- a mixture containing drilling fluid and cuttings is then returned to the surface through and annulus around the drill pipe “Adherent drilling fluid” is defined as drilling fluid adhering to the drill cuttings, and, if the drilling fluid is oil-based, the adherent drilling fluid also includes oil.
- Hart suggests that, due to environmental concerns, much of the slurry is transported in a fluid or semi-fluid state to approved disposal sites. Such sites utilize deep wells whereby hazardous waste can be injected back into the earth or mixed with chemicals such as lye and fly ash which render the materials acceptable for land reclamation. Disposal sites may also provide centrifuges as a means of defluidizing the slurry and rely heavily on polymers added to the effluent to render the discharge liquids safe for reintroduction into the environment.
- Many recovery and treatment apparatus utilize separate cells having low speed agitators to stir a mixture of cutting and cleansing solution called surfactants.
- the cuttings are transferred from one cell to the next where additional agitation and cleansing take place.
- a slurry of cleansed drill cuttings and surfactant is pumped from the cells to a vibrating screen operation whereby most of the surfactant is removed and sent back to the system.
- a portion of the surfactant solution which is rich in fine drill cuttings and adherent drilling fluids, is run through one or more hydrocyclone separators which discharge the fine drill cuttings in solution separated from the larger, cleansed drill cuttings.
- screw presses have been widely used in the agricultural industry to dewater fibrous slurries, such presses have not gained acceptance in the earth drilling industry for a number of reasons. Compressing earth cuttings developed from drilling operations would be difficult under most conditions, due to the volume, the abrasiveness, and nonuniformity of such materials. Dewatering screw conveyors and screen conveyor systems have been used with some success in mining operations to remove a large portion of the residual water. However, the drilling additives associated with petroleum drilling operations make defluidizing more complicated. It has been found that screw presses, such as disclosed by Eichler in U.S. Pat. No. 5,009,795, could serve as the basis for a defluidizing press in the present invention concept.
- a defluidizing type press designed specifically to handle a slurry of drill cuttings may be utilized to recover drilling fluids while defluidizing the discharge cuttings, thereby resulting in a savings of costly drilling additives and reducing the volume of discharge into the environment.
- Such savings are further enhanced as a result of a reduction in environmental additives, such as lime and fly ash, and other such chemicals used to neutralize the discharge waste material when being reintroduced into the environment.
- environmental additives such as lime and fly ash, and other such chemicals used to neutralize the discharge waste material when being reintroduced into the environment.
- the present invention provides a means of recovery of drilling fluids from drilling fluid slurries containing entrained solids. Such slurries are derived directly from the cascading, vibrating screens in various drill cutting processing systems. It has been found that any discharge from such systems which is considered suitable for disposal into the environment can now be cycled through a defluidizing press whereby up to 40% by volume of the remaining drilling fluids can be recovered in the defluidization process.
- a second defluidizing press may be used to further reduce the fluid content, thereby reducing the discharge volume.
- defluidizing presses may be capable of replacing all or a significant part of the current processes, thus eliminating the cascading screens, hydrocyclones, and centrifuges. It should be understood that although the majority of the fluids from the cuttings are being recovered by utilizing the screw press and liquid screen as taught herein, the solids still retain a relatively high moisture content and still retain some petrochemicals. It is also desirable, in some cases, to reduce the solids to their lowest possible mass for transport and disposal into the environment. Therefore, systems also may be provided that utilize the defluidizing technology that allows the defluidized cuttings to be further processed for transport and disposal in the environment.
- Such systems may simply include further treatment of the defluidized cuttings with chemicals to disperse the petrochemicals and assist in the biodegradation of the solids prior to reintroduction into the environment.
- Other more elaborate systems as taught herein also utilize the combustible petrochemical in the cuttings to assist in drying the solids prior to mixing environmentally enhancing chemicals.
- Defluidized cuttings may be disposed of in any number of ways as disclosed herein, such as reinduction into well casing, transported, at a reduced volume cost, for injection at processing and disposal sites, or to distillation and land reclamation farms where fewer chemicals will be required to treat the materials prior to introduction into the environment.
- an object of the present invention to provide a means of recovery of a greater percentage of drilling fluids currently being lost in the disposition process.
- Still another object of the invention is to reduce the quantity of fluids being transported for disposition, thereby making transport of disposable drill cuttings more economical.
- Yet another object of the present invention is to reduce the drilling additives in the disposable cuttings, thereby reducing the quantity of biodegradation additives generally required by land farms.
- FIG. 1 is a diagram of the present invention in section view shown receiving slurry from a shaker screen system and discharging defluidized material to a well injection system, to cutting box for disposal at a hazardous waste site, or to a truck for disposition into a distillation process or the environment;
- FIG. 2 is a partial cross section view of a system tank and the present invention mounted thereto, showing slurry material being discharged into a hopper;
- FIG. 3 is a partial cross section view of a system tank and the present invention mounted thereto, showing an infeed screw conveyor coupled directly to the feed screw of the present invention;
- FIG. 4 is a an isometric view of the present invention.
- FIG. 5 is a cross sectional elevation and piping diagram of a two press system utilizing a circulating tank
- FIG. 6 is a cross section elevation showing the present invention discharging into a pug mill having chemical infeed capability
- FIG. 7 is a cross section elevation of a second embodiment of the press having hydraulic ram feed
- FIG. 9 is a side elevation of the piston pump in FIG. 8;
- FIG. 10 is a side elevation and cross section of a screw press having means for applying pressure or vacuum to the defluidizing means
- FIG. 11 is a partial cross section of the screen element
- FIG. 12 is an illustration of a vibrator and band assembly located around the sieve screen
- FIG. 13 is a partial cross section view of the drive motor mounted to the screw shaft
- FIG. 14 is a vertical cross section view illustrating a cuttings drying system utilizing the disclosed technology
- FIG. 15 is a partial top view of the system illustrated FIG. 14.
- FIG. 16 is a vertical cross section of an alternative system utilizing the disclosed technology.
- FIG. 1 where the major components of the defluidization recovery system 10 starts with drill cuttings and drilling fluids in a slurry 16 collected from any source as overflow or underflow, usually from the rig's shaker screens (not shown).
- the slurry 16 is transported via a conveyor 18 to the screw press 20 , shown here in cross section and better seen in FIG. 2, mounted on top of a fluid recovery tank 14 , illustrating the flow path of the slurry 16 being defluidized.
- a screw press 20 or other compaction type presses depicted herein, having particular characteristics, could be mounted on or near a drilling fluids system tank 14 in which case drilling fluids contained in the overflow and underflow slurry 16 could be separated from the drill cuttings processing system prior to discharge into the environment.
- the slurry 16 in most cases, contains valuable drilling additives including synthetics and/or surfactants which, after having passed through a wash system (not shown), could be fed via a screw conveyor 18 to the press 20 where the slurry 16 is defluidized.
- the cuttings, contained in the slurry 16 when compacted in the press 20 , as a result of being forced through a compaction zone 25 , forces the drilling fluids 22 , which containing valuable drilling additives, to be discharged into the system tank 14 for recirculation in the drilling process.
- the separated defluidized cuttings residue 24 is then discharged via a discharge chute 26 to a drill cuttings injection system 28 , to a cutting storage box 30 , or to a transporting vehicle 32 for transport to a hazardous waste site for injection in a deep well 34 , or treated for environmental disposal at a land reclamation farm 36 .
- the slurry 16 may be conveyed to the press 20 in any accepted manner, such as screw conveyor 18 , gravity feed, or by pump.
- Valves 60 , 60 ′ located below the hopper 52 open alternately to allow the slurry to pass to each ram tube 54 , 54 ′ via valve 62 .
- an operating system reverses the piston 56 travel, whereby the valve 60 located below the hopper 52 is then closed simultaneously with valves 62 ′ being opened at the entrance to the ram tube 54 ′, juxtaposed the ram tube 54 , being filled, and sequentially opening the discharge valve 63 located between the discharge merging element 66 and the press screen 74 , the piston 56 then moves forward in the first cylinder 54 , thereby expelling the slurry 16 , while additional slurry material 16 is being taken into the second tube 54 ′ by hydraulic ram cylinder 581 and piston 56 ′ (not shown).
- each ram tube 54 , 54 ′ is then forced into the 30 merging connector 66 .
- a solids discharge zone at the end of the discharge tube 70 is essentially the same for all the presses disclosed herein. Restriction cylinders 68 are controlled remotely, thereby establishing the opening 72 between conical plug 80 and seat 82 thus providing compaction of the solids residue 24 .
- the slurry 16 under pressure from the ram piston, 56 forces the slurry 16 linearly through a strainer screen 74 .
- a strainer screen 74 As a result of compaction in the discharge tube 70 , fluids less than 50 micron are expelled through a screen sieve 74 .
- the expunged fluid 22 is then returned to the system tank 14 while the more dense solids residue 24 greater than 50 micron is forced through the discharge tube 70 .
- the system then reverses the operation for the alternate ram cylinder 58 ′, thus creating a push pull operation. Therefore, while one ram cylinder 54 is filling, the adjacent cylinder 54 ′ is being discharged.
- the solids residue 24 being forced through the discharge tube 70 is thereby extruded at a steady rate, controlled by the gap 72 between the elliptical plug 80 and its seat 82 .
- the length of the discharge tube 70 and ambient temperature further enhance compaction, thus further reducing the moisture content of the discharge material 24 .
- the screw press 20 assembly as shown in FIG. 4 provides a better understanding of the requirement of a defluidizing press when applied to drilling fluid slurry 16
- the slurry 16 is seldom consistent with respect to its volume or its density and, therefore, a positive means of controlling the restriction plug 80 is essential.
- Drilling fluid slurry 16 may vary in its consistency and at times may contain as little as 10% solids.
- Screw presses 20 have a tendency to become static when insufficient solids are present. Other press types and embodiments are disclosed herein which are capable of solving these problems. If a screw press 20 is used, it must have a more positive means of sealing between the screw flighting 90 and the cylindrical walls 92 as seen in FIG. 3 . It is also imperative that the orifices 96 shown in FIG.
- FIG. 10 Another method of reducing static conditions and/or cavitation are shown in FIG. 10, wherein a valve 100 is applied between the infeed hopper 38 and the feed screen 74 and a vacuum line 101 and valve 102 are connected to the defluidizing zone 104 .
- This negative pressure increases flow and insures a positive flow of recovered fluid 22 through the defluidizing screens 74 .
- a positive pressure may also be used to increase flow through the defluidizing zone 104 through the use of air nozzles 106 located in the inflow zone 108 .
- a chemical such as calcium carbonate
- a screw press 20 may also he used in conjunction with a pug mill 5 , whereby chemicals 3 such as lime and fly ash are mixed with the solid cuttings residue 24 prior to discharge into the environment.
- restriction in the compaction zone 25 of the discharge portion is effected in most cases by a pair of cylinders 68 disposed parallel either side the linear axis of the discharge flange 82 .
- the cylinders 68 are adjusted remotely to position the conical restriction member 80 relative to the discharge flange 82 , thereby providing infinite positive control of the discharge of defluidized material 24 .
- the compacted solids 24 have a natural tendency to adhere to the inside diameter of the screen 74 . It has been found that a relatively small vibrator 140 can be placed on the outer diameter of the screen in the manner illustrated in FIG. 12, thus imparting a vibration over the face of the screen eliminating much of the material adhesion.
- the screw press 20 is divided into three zones, 30 :
- the infeed zone comprising a hopper 38 having an overflow tube 44 , the hopper 38 located above and adjacent to the screw infeed compartment 108 , a defluidizing zone 104 , a fluid discharge 22 as illustrated in FIG. 2 and 3, and a solids discharge zone 25 .
- the slurry 16 containing solids and drilling additives to be separated, is conveyed to the infeed hopper 38 and thus to the screw press 20 where any excess fluid is vented off through the overflow pipe 44 . Most of the fluids in the slurry 16 are drained off through the separator strainers 74 in the defluidizing zone 104 prior to compaction.
- the typical screw press of the present invention comprises a base frame 99 having vertical supports 109 , 116 , 118 , and 120 extending upwardly therefrom; an infeed zone comprised of a hopper portion 38 mounted to a tubular infeed housing 108 , having a flange fitting at each end, one end of which is supported inboard to vertical support 109 with the opposite end attached to one side of support 118 .
- the press further comprises a driver motor 42 mounted to the external flange housing 43 , shown in FIG. 4, secured to the outboard side of the vertical support 109 adjacent the infeed housing 108 .
- the drive motor shaft 107 is coupled directly to an output shaft 111 , extending through the external flange housing 43 , and held in axial alignment by a head shaft bearing 113 located within the external flange housing 43 .
- the hollow screw shaft 111 is fitted with an internal spine which engages the drive motor output shaft 107 .
- Shaft 111 fitted with helical screw flighting 90 shown in cross section in FIG.
- the shaft 111 is rotatably supported by a flange bearing 115 mounted to vertical support 116 .
- the press further comprises a defluidizing zone 110 adjacent to the infeed zone, separator strainers 74 , a collection chamber 104 surrounding the strainers, and a fluid discharge aperture 114 below the strainer passing through the base frame 99 .
- the separator strainer or sieve screen 74 as illustrated in FIG. 11 comprises a 50 micron screen 94 backed by a plurality of wedged shaped, axially extending, parallel slats 97 held in an equally spaced, circumferential relationship by multiple supporting rings 93 , slats 97 having a spacing between their widest portion of precisely 0.004 of an inch for 50 micron separators used for most drilling fluid recovery systems, with larger spacing used for greater micron screening for primary or special applications.
- Slats are formed into a radial diameter coinciding with the inside diameter of the infeed housing.
- flanges corresponding to the infeed housing discharge flange are secured to each end of the wedged shaped slats, thereby defining a flanged tubular section.
- At least three torsion members secured to and extending axially between the flanges are attached to each of the supporting rings, providing a ridged, structural unit. Any number of these strainer sections may be connected together and utilized as necessary to provide sufficient separation of the entrained solids.
- the strainer flange adjacent the discharge is secured to a vertical frame member 118 having a diametrical bore equal to the flange inside diameter.
- the screw press further comprises a discharge zone comprising a flanged reducing tubular portion 82 having an internal diameter less than an internal diameter of the strainer screen sieve 74 , the reducing flange 82 being mounted to the discharge side of the base frame, vertical support ember 120 adjacent the defluidization zone 110 , a conical disk 80 , slidable along the screw shaft 111 , operated by a pair of ram cylinders 68 connected to a collar 69 at the back side of the conical disk.
- the screw press 20 may be driven by a drive motor 42 by direct coupling to the infeed conveyor 18 as seen in FIG. 3, or by pistons as illustrated in FIGS. 7, 8 , and 9 .
- the slurry 16 is urged through the defluidizing zone 110 towards the discharge zone 25 .
- such flighting ends just short of the restriction element 80 , as does the piston stroke.
- the elliptical restriction element 80 is slidable and rotatably fitted over the hollow feed screw shaft 111 , thereby allowing the restriction element 80 to be positioned at various positions adjacent the discharge flange 82 , such positioning being controlled by positioning cylinders 68 disposed on each side of the extension shaft 111 and attached to the elliptical restriction element 80 .
- the positioning cylinders may be controlled remotely or manually adjusted. Rotation of the restriction element 80 is prevented relative to the rotating screw shaft 111 by torque arresters 121 . With the restriction element 80 positioned in close proximity to the discharge flange 82 , the discharge of the semi-dry drill cuttings 24 can be innitely controlled.
- the defluidization zone 110 defining an enclosure 104 surrounding the screen 74 , enhances the ability of the press 20 to remove fluids rapidly. It has been found that a screen sieve 74 having a 50 micron admissibility is sufficient to recover most drilling additives in the slurry 16 . It has also been found that a residue 24 moisture content of less than 40% can be achieved.
- a primary press of this nature can remove 40% by volume of the oil or water in a slurry 16 directed from the rig's cuttings shaker system, thereby reducing the moisture content of the discharge material 24 to as little as 13.4% liquid by weight.
- a second stage press 10 ′ operation as illustrated by FIG. 5 could reduce the liquid content of the disposable cuttings 24 to less than 10% by wt.
- a circulating tank 27 may be necessary to maintain the slurry in solution.
- a system of pumps 31 , 31 ′ and valves 33 , 33 ′ for moving the fluids from the recirculating tank to the second stage press and from the second stage press back to the recirculating tank or system tank may also be needed.
- the semidry cuttings 24 being discharged from the press 10 may also be further processed by feeding the cuttings to the feed bin 200 of a rotary kiln 202 .
- the petrochemical coated cuttings are fed into the kiln and ignited, the petrochemicals are driven off in vapors through the exhaust stack, recycled to the burner 206 , or otherwise environmentally controlled as known within the art.
- the dried and sterile cutting solids are then moved by conveyer 210 to a collection container for deposit into one or more of the collection and transport or distribution means illustrated in FIG.
- FIG. 15 A plan view of the flow path is best seen in FIG. 15 .
- the semidry solids 24 may also be deposited directly into the fine grinder and the mixing mill 5 without drying the solids, in which case the fine solids are then combined with slurry additives which enhance flow of the solids for injection back into the earth formations through the high-pressure injection pump system 28 seen in FIG. 1
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
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- General Life Sciences & Earth Sciences (AREA)
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Abstract
Description
Claims (3)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/454,081 US6279471B1 (en) | 1995-09-15 | 1999-12-03 | Drilling fluid recovery defluidization system |
US09/906,944 US6553901B2 (en) | 1996-09-13 | 2001-07-16 | Drilling fluid recovery and cuttings processing system |
US10/424,297 US6910411B2 (en) | 1996-09-13 | 2003-04-28 | Drilling fluid recovery and cuttings processing system |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US378195P | 1995-09-15 | 1995-09-15 | |
US08/713,604 US5996484A (en) | 1995-09-15 | 1996-09-13 | Drilling fluid recovery defluidization system |
US09/454,081 US6279471B1 (en) | 1995-09-15 | 1999-12-03 | Drilling fluid recovery defluidization system |
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US08713604 Continuation-In-Part | 1966-09-13 | ||
US08/713,604 Continuation-In-Part US5996484A (en) | 1995-09-15 | 1996-09-13 | Drilling fluid recovery defluidization system |
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US09/906,944 Continuation-In-Part US6553901B2 (en) | 1996-09-13 | 2001-07-16 | Drilling fluid recovery and cuttings processing system |
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US09/454,081 Expired - Lifetime US6279471B1 (en) | 1995-09-15 | 1999-12-03 | Drilling fluid recovery defluidization system |
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Cited By (52)
Publication number | Priority date | Publication date | Assignee | Title |
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US20010050006A1 (en) * | 2000-04-28 | 2001-12-13 | Kanji Nakamura | Recycle of grinding sludge |
US6461523B1 (en) * | 2000-03-23 | 2002-10-08 | John Greenrose | Solids separation mechanism |
US20030192439A1 (en) * | 1996-09-13 | 2003-10-16 | Jeffrey Reddoch | Drilling fluid recovery and cuttings processing system |
WO2003102359A1 (en) | 2002-05-31 | 2003-12-11 | Baker Hughes Incorporated | Centrifugal drill cuttings drying apparatus. |
US6681874B2 (en) | 2002-01-23 | 2004-01-27 | Drill Cuttings Technology, L.L.C. | Method and apparatus for removing fluids from drill cuttings |
US6698989B2 (en) | 1999-06-16 | 2004-03-02 | Cleancut Technologies Limited | Pneumatic conveying |
US20040154963A1 (en) * | 2003-02-10 | 2004-08-12 | Jerry Rayborn | Polymer drilling bead recovery system & related methods |
US20040182605A1 (en) * | 2003-03-19 | 2004-09-23 | Seyffert Kenneth W. | Positive pressure drilled cuttings movement systems and methods |
US20040219247A1 (en) * | 1999-09-22 | 2004-11-04 | Helmut Bacher | Process and apparatus for recycling of PET-material |
US20050023038A1 (en) * | 2003-08-01 | 2005-02-03 | Seyffert Kenneth W. | Drilling systems |
US20050074302A1 (en) * | 2001-09-04 | 2005-04-07 | Varco I/P, Inc. | Apparatus and method for transporting waste materials |
US20050183994A1 (en) * | 2004-02-11 | 2005-08-25 | Hutchison Hayes, L.P. | Integrated Shale Shaker and Dryer |
US20050183574A1 (en) * | 2003-03-19 | 2005-08-25 | Burnett George A. | Systems and methods for storing and handling drill cuttings |
US20060102390A1 (en) * | 2003-03-19 | 2006-05-18 | Burnett George A | Drill cuttings conveyance systems and methods |
US20070081866A1 (en) * | 2005-10-07 | 2007-04-12 | Deal Benny J | Methods and systems for delivering lost circulation material into drilling pits |
US20070131454A1 (en) * | 2005-12-13 | 2007-06-14 | Baker Hughes Incorporated | Drill cuttings transfer system and related methods |
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